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- Laser beam welding (19)
- Additive Manufacturing (9)
- Solidification cracking (9)
- Inconel 718 (7)
- Numerical simulation (7)
- Additive manufacturing (5)
- DED (5)
- Laser Metal Deposition (5)
- AM (4)
- Additive Fertigung (4)
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- Laserstrahlschweißen (4)
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- Ti-6Al-4V (4)
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- 316L (3)
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- Elektromagnetische Schmelzbadunterstützung (3)
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- Stainless Steel (3)
- AISI D2 (2)
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- CTW-Test (2)
- Critical strain (2)
- Defokussierung (2)
- Directed Enery Deposition (2)
- Duplex stainless steel (2)
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- Elektronenstrahlschweißen (2)
- Element transport (2)
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- GMAW (2)
- High power laser beam welding (2)
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- Hybrid Laser Arc Welding (2)
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- Laser-Hybridschweißen (2)
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- TiB2 (2)
- Transient heat transfer (2)
- WAAM (2)
- Weld pool dynamics (2)
- Überlappbereich (2)
- 3DDruck (1)
- 9%Ni steel, (1)
- Additiv (1)
- Additive (1)
- Advanced high strength steels (1)
- Al-Mg-Si-Legierungen (1)
- Al/Mg alloys (1)
- Alloy 247 (1)
- Aluminium-Druckguss (1)
- Analytical model (1)
- Arc sensor (1)
- Artungleiche Werkstoffe (1)
- Aufbaustrategie (1)
- Auftriebskräfte (1)
- Austenitische Stähle (1)
- Automation (1)
- Automatisierung (1)
- Bewegtes Gitter (1)
- Build - up Strategy (1)
- Build direction (1)
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- CFD-model (1)
- CTW test (1)
- Calculation time (1)
- Charpy impact toughness (1)
- Cold Cracking Test (1)
- Combined laser manufacturing (1)
- Conventional Ni-based austenitic welding electrode (1)
- Cracking susceptibility (1)
- Cracking susceptibility of AHSS (1)
- Cryogenic Steel (1)
- Cryogenic steel (1)
- Crystal branch development (1)
- CuSn1 (1)
- DED-EB (1)
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- Dickblech (1)
- Die-cast aluminum (1)
- Different welding position (1)
- Digitale Bildkorrelationstechnik (1)
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- Direct Energy Deposition (1)
- Direct Laser Metal Deposition (1)
- Directed energy deposition (1)
- Distortion simulation (1)
- EBAM (1)
- Efficient modelling (1)
- Einfluss auf Schweißeigenspannungen (1)
- Electromagnetic Force (1)
- Electromagnetic Weld Pool Support (1)
- Electromagnetic influence (1)
- Electron beam (1)
- Elektonenstrahlschweißen (1)
- Elektromagnetische Porenreduktion (1)
- Elektromagnetische Schmelzbadbeeinflussung (1)
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- End-crater (1)
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- Equivalent volumetric heat source (1)
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- FE simulation (1)
- FE-model (1)
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- Ferritic welding electrode (1)
- Filler material distribution (1)
- Finite element method (1)
- Flow pattern (1)
- Friction spot welding (1)
- Friction stir welding (1)
- Full Penetration (1)
- Functionally Graded Materials (1)
- Funktionally Graded Material (1)
- Fügequalität (1)
- Fügetechnologie (1)
- Gaps (1)
- Grain refinement (1)
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- Heat treatment (1)
- Heat treatments (1)
- Heißriss (1)
- Heißrissanfälligkeit (1)
- Heißrisse (1)
- Heißrissresistenz (1)
- High power laser keyhole welding (1)
- High power welding (1)
- High-power Laserbeam Welding (1)
- Hochleistungslaserstrahlschweißen (1)
- Hochleistungsschweißen (1)
- Hybrid Part (1)
- Hybrid laser arc welding (1)
- Hybrid laser-arc welding (1)
- Hybrid-laser-arc welding (1)
- In situ strain (1)
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- Intensity of Restraint (1)
- KI (1)
- Keyhole collapse (1)
- Keyhole mode laser beam welding (1)
- Keyhole mode welding (1)
- Knotenweise Zwangsbedingungen (1)
- Künstliche Intelligenz (1)
- Künstliche Neuronale Netze (1)
- Künstliche neuronale Netze (1)
- L-PBF (1)
- LCA (1)
- LW (1)
- Laser (1)
- Laser Metal Deposition; Laser Beam Welding; Duplex; Stainless Steel (1)
- Laser Powder Bed Fusion (1)
- Laser Welding (1)
- Laser beam Welding (1)
- Laser dispersing (1)
- Laser energy distribution (1)
- Laser metal deposition (LMD) (1)
- Laser- und Lichtbogenenergie (1)
- Laser-Metal-Deposition (1)
- Laser-Pulver-Auftragschweißen (LPA) (1)
- Laser-Pulver-Auftragschweißen; Laserstrahlschweißen, Duplex, Pufferschichten (1)
- Laser-beam welding, (1)
- Laser-metal-deposition (1)
- Laser-plasma hybrid (1)
- Laserdispergieren (1)
- Laserpulverauftragschweißen (1)
- Laserstrahl-(Hybrid)schweißen (1)
- Laserstrahl-MSG-Hybridschweißen (1)
- Liquation Cracking (1)
- Liquid metal embrittlement (1)
- Low Temperature Toughness (1)
- MAG Prozesssteuerung (1)
- MSG-Engspaltschweißen (1)
- Macro Processing (Joining, Welding) (1)
- Magnesium (1)
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- Multi - physical modeling (1)
- Multi-attribute decision method (1)
- Multi-criteria decision support (1)
- Narrow-gap welding (1)
- Neural network (1)
- Neuronales Netz (1)
- Nickel-based superalloy (1)
- Nickelbasis-Superlegierungen (1)
- Numerical modelling (1)
- Numerical process simulation (1)
- Numerische ISmulation (1)
- Optical measurement (1)
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- Optische Emissionsspektroskopie (OES) (1)
- Oscillating magnetic field (1)
- Oscillating vapor plume (1)
- PBF-LB/M (1)
- PBF/LB-M (1)
- Partial penetration (1)
- Path planning (1)
- Pendelstrategie (1)
- Penetration depth (1)
- Periodic solidification pattern (1)
- Phänomenologisch (1)
- Pipeline steel X120 (1)
- Plasma-Transferred-Arc (1)
- Plasma-transferred-arc (1)
- Pointwise constraints (1)
- Porosity reduction (1)
- Porosität (1)
- Powder Analysis (1)
- Pre-weld Preparation (1)
- Process chain (1)
- Process simulation (1)
- Profilvermessung (1)
- Prozesssimulation (1)
- Pulverbettbasiert (1)
- Ray tracing (1)
- Ray tracing method (1)
- Ray-tracing (1)
- Recycling (1)
- Refill friction stir spot welding (1)
- Repair and overhaul (1)
- SEP-1220-3 (1)
- SLM (1)
- SLM printed plasma torch (1)
- SMAW (1)
- Schallemissionsanalyse (SEA) (1)
- Schweißen von kaltzähen Stählen (1)
- Schweißsimulation (1)
- Schweißstruktursimulation (1)
- Self-restraint test (1)
- Sensorik (1)
- Simulation (1)
- Solidification (1)
- Solidification behaviour (1)
- Solidification craking (1)
- Spiralstrategie (1)
- Spurgröße (1)
- Stahl und Aluminium (1)
- Steel (1)
- Strain rate (1)
- Superelliptic Lamé curves (1)
- Surface structuring (1)
- Surface texturing (1)
- TRIP (1)
- Tandem Gas Metal Arc Welding (1)
- Temperaturentwicklung (1)
- Tensile performance (1)
- Tensile strength (1)
- Thermo-capillary convection (1)
- Thermo-fluid flow (1)
- Thermographie (1)
- Thermography (1)
- Thermomechanisch (1)
- Thick Materials (1)
- Thick metal plate welding (1)
- Thick-walled steel (1)
- Ti - 6Al - 4V (1)
- Turbine industry (1)
- Turbulence (1)
- Ultrasonic vibration (1)
- Umwandlungsplastischen Konstante K (1)
- Untersuchung laserstrahlgeschweißter Verbindungen (1)
- Vacuum (1)
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- WEBAM (1)
- Weld pool (1)
- Weld pool geometry (1)
- Weld pool shape approximation (1)
- Welding costs (1)
- Welding process selection (1)
- Welding simulation (1)
- Welding under external loading (1)
- Widerstandspunktschweißen (1)
- Wire Electron Beam Additive Manufacturing (1)
- Wire electron beam additive manufacturing (1)
- Wärmenachbehandlung (1)
- X8Ni9 (1)
- deposition welding (1)
- highspeed plasma laser cladding (1)
- laser energy distribution (1)
- laser hybrid welding (1)
- thermal cycles (1)
- thick plate welding (1)
- Äquivalente Wärmequelle (1)
Organisationseinheit der BAM
- 9 Komponentensicherheit (71)
- 9.3 Schweißtechnische Fertigungsverfahren (69)
- 9.6 Additive Fertigung metallischer Komponenten (2)
- 1 Analytische Chemie; Referenzmaterialien (1)
- 1.9 Chemische und optische Sensorik (1)
- 8 Zerstörungsfreie Prüfung (1)
- 8.0 Abteilungsleitung und andere (1)
- 8.1 Sensorik, mess- und prüftechnische Verfahren (1)
Der Einsatz von Hochleistungswerkstoffen verlangt nach einer hohen Endformnähe der zu fertigenden Bauteile, um den Aufwand und somit die Kosten für Materialeinsatz und Nachbearbeitung möglichst gering zu halten. Der additive Einsatz in Form des Laser-Pulver-Auftragschweißens bietet hierfür durch den gezielten Materialauftrag ein hohes Potential. Herausforderungen bestehen in Bereichen der Vorhersagbarkeit und der Reproduzierbarkeit des Materialauftrages, sowie der Fertigungszeit. Unterschiedliche Einflüsse bei der Schichterzeugung führen dabei zu Abweichungen von der Soll-Geometrie. Die vorliegenden Untersuchungen behandeln den Einfluss von Spurgeometrie, Spurüberlappung, Verfahrweg und Aufbaureihenfolge auf die entstehende Bauteilform. Die Teilung einer Lage in Rand- und Kernbereich ermöglicht einen konturangepassten Verfahrweg und eine Erhöhung der Endformnähe innerhalb einer Ebene. Die Verwendung unterschiedlicher Spurgrößen bei der Bauteilerzeugung verdeutlicht die Möglichkeiten einer hohen Auftragsrate bei gleichzeitig hoher Formgenauigkeit. Bereits kleine Unterschiede beim Materialauftrag zwischen Kern- und Randbereichen, Start- und Endpunkten sowie in Bereichen des Richtungswechsels führen aufgrund von Fehlerfortpflanzung nachmehreren Lagen zu Abweichungen in der Aufbaurichtung. Kompensierungen mittels angepasster Baustrategien werden aufgezeigt und diskutiert. Die Nickelbasislegierung Inconel 718, die Titanlegierung Ti-6Al-4V sowie der austenitische Stahl 316L sind Bestandteil der vorliegenden Untersuchungen. Die gewonnenen Erkenntnisse verdeutlichen das Potenzial einer angepassten Aufbaustrategie zur reproduzierbaren Erzeugung von Bauteilen am Beispiel unterschiedlicher Körpergeometrien.
Laser welding is a widely established manufacturing process in many industry sectors. Solidification cracking represents one of the most inadequately solved problems in welding and has major economic implications. The avoidance of hot crack is for most fusion welding processes a key challenge for an important range of metallic construction materials and affects not only the manufacturers of welding equipment and material manufacturers, but also a large number of customers using welding technologies, as well as welding standardization and research. In this study a new investigation programme has been developed to qualify the hot cracking susceptibility of a variety of austenitic stainless steels. The results show the possibility of using this technique to determinate the critical values that occur with initiation of solidification cracking during laser beam welding
Laser welding is a widely established manufacturing process in many industry sectors. Solidification cracking represents one of the most inadequately solved problems in welding and has major economic implications. The avoidance of hot crack forms for most fusion welding processes poses a key challenge for an important range of metallic construction materials and affects not only the manufacturers of welding equipment and material manufacturers, but also a large number of customers using welding technologies, as well as welding technical standardization and research. Solidification cracking susceptibility was examined with the help of the Controlled Tensile Weldability Test (CTW) developed by Federal Institute for Materials Research and Testing (BAM), Berlin. The test is based on the fact that hot crack formation depends on a critical strain that emerges within a critical temperature range, the so called brittle temperature range (BTR). Using this test and defined investigation programme a centreline solidification crack was generated. By controlling the applied strain during the laser beam welding process, it was possible to determine the critical strain and strain rate that led to solidification cracking formation. The hot cracking susceptibility of the tested stainless steels was qualified and quantified. The results demonstrate that the crack length increases with increasing applied strain. Furthermore, the strain rate has a significant influence on the formation of the solidification crack.
Increasing performance and energy efficiency of Gas Metal Arc Welding by a high power tandem process
(2016)
Standard Gas Metal Arc Welding (Standard GMAW) and a high power Tandem GMAW (TGMAW) process are evaluated with respect to energy efficiency. Current, voltage and overall equipment power are measured and energy consumption is determined. The new key performance indicator Electrical Deposition Efficiency is introduced to reflect the energy efficiency of GMAW processes. Additionally, wallplug efficiency of the equipment is determined in order to identify the overall energy consumption. Results show that energy efficiency as well as economic process performance can be significantly increased by application of the TGMAW process. Furthermore findings indicate that wall-plug efficiency of the equipment is independent of power level and material transfer mode. A metal plate of 30 mm thick structural steel is joined by Standard GMAW and TGMAW to demonstrate the total energy savings for a real weld. Electricity consumption is reduced by more than 20 % using the high power TGMAW process.
Selecting a welding process for a given application is crucial with respect to the sustainability of part manufacturing. Unfortunately, since welding processes are evaluated by a number of criteria, preferences for one or the other process can be contradictory. However, the prevalent procedure of weight assignment for each criterion is subjective and does not provide information about the entire solution space. From the perspective of a decision maker it is important to be able to assess the entire set of possible weightings and answer the question which welding process is optimal for which set of weights. This issue is investigated by means of a weight space partitioning approach. Two welding processes are considered with respect to three criteria that reflect their economic and environmental performance. In order to find the most sustainable welding process the underlying weight space partition is evaluated.
Spot welding is one of the most important joining technologies, especially in the automotive industry. Hitherto,the quality of spot welded joints is tested mainly by random destructive tests. A nondestructive testing technique offers the benefit of cost reduction of the testing procedure and optimization of the fabrication process, because every joint could be examined. This would lead to a reduced number of spot welded joints, as redundancies could be avoided. In the procedure described here, the spot welded joint between two zinc-coated steel sheets (HX340LAD+Z100MB or HC340LA+ZE 50/50) is heated optically on one side. Laser radiation and flash light are used as heat sources. The melted zone, the so called “weld nugget” provides the mechanical stability of the connection, but also constitutes a thermal bridge between the sheets. Due to the better thermal contact, the spot welded joint reveals a thermal behavior different from the surrounding material, where the heat transfer between the two sheets is much lower. The difference in the transient thermal behavior is measured with time resolved thermography. Hence, the size of the thermal contact between the two sheets is determined, which is directly correlated to the size of the weld nugget, indicating the quality of the spot weld. The method performs well in transmission with laser radiation and flash light. With laser radiation, it works even in reflection geometry, thus offering the possibility of testing with just one-sided accessibility. By using heating with collimated laser radiation, not only contactfree, but also remote testing is feasible. A further convenience compared to similar thermographic approaches is the applicability on bare steel sheets without any optical coating for emissivity correction. For this purpose, a proper way of emissivity correction was established.
An electromagnetic weld pool support system for 20 mm thick duplex stainless steel AISI 2205 was investigated numerically and compared to experiments. In our former publications, it was shown how an AC magnetic field below the process zone directed perpendicular to the welding direction can induce vertically directed Lorentz forces. These can counteract the gravitational forces and allow for a suppression of material drop-out for austenitic stainless steels and aluminum alloys. In this investigation, we additionally adopted a steady-state complex magnetic permeability model for the consideration of the magnetic hysteresis behavior due to the ferritic characteristics of the material. The model was calibrated against the Jiles-Atherton model. The material model was also successfully tested against an experimental configuration before welding with a 30 mm diameter cylinder of austenitic stainless steel surrounded by duplex stainless steel. Thereby, the effects of the Curie temperature on the magnetic characteristics in the vicinity of the later welding zone were simulated. The welding process was modelled with a 3D turbulent steady-state model including heat transfer and fluid dynamics as well as the electromagnetic field equations. Main physical effects, the thermo-capillary (Marangoni) convection at the weld pool boundaries, the natural convection due to gravity as well as latent heat of solid–liquid phase transitions at the phase boundaries were accounted for in the model. The feedback of the electromagnetic forces on the weld pool was described in terms of the electromagneticinduced pressure. The FE software COMSOL Multiphysics 4.2 was used in this investigation. It is shown that the gravity drop-out associated with the welding of 20 mm thick duplex stainless steel plates due to the hydrostatic pressure can be prevented by the application of AC magnetic fields between around 70 mT and 90 mT. The corresponding oscillation frequencies were between 1 kHz and 10 kHz and the electromagnetic AC powers were between 1 kW and 2.3 kW. In the experiments, values of the electromagnetic AC power between 1.6 kW and 2.4 kW at oscillation frequencies between 1.2 kHz and 2.5 kHz were found to be optimal to avoid melt sagging or drop-out of melt in single pass fullpenetration laser beam welding of 15 mm and 20 mm thick AISI 2205.
Full penetration high power bead-on-plate laser beam welding tests of up to 20 mm thick 2205 duplex steel plates were performed in PA position. A contactless inductive electromagnetic (EM) weld pool support system was used to prevent gravity drop-out of the melt. Welding experiments with 15 mm thick plates were carried out using IPG fiber laser YLR 20000 and Yb:YAG thin disk laser TruDisk 16002. The laser power needed to achieve a full penetration was found to be 10.9 and 8.56kW for welding velocity of 1.0 and 0.5 m min(-1), respectively. Reference welds without weld pool support demonstrate excessive root sag. The optimal value of the alternating current (AC) power needed to completely compensate the sagging on the root side was found to be approximate to 1.6 kW for both values of the welding velocity. The same EM weld pool support system was used in welding tests with 20 mm thick plates. The laser beam power (TRUMPF Yb:YAG thin disk laser TruDisk 16002) needed to reach a full penetration for 0.5 m min(-1) was found to be 13.9 kW. Full penetration welding without EM weld pool support is not possible-the surface tension cannot stop the gravity drop-out of the melt. The AC power needed to completely compensate the gravity was found to be 2 kW. (C) 2016 Laser Institute of America